PERMANENT MOLD CASTING

MODULE – 2B

1
LEARNING OBJECTIVES
 Basic Permanent Mold Casting
 Slush Casting
 Pressure Casting
 Vacuum Permanent Mold Casting
 Die Casting
 Hot Chamber Die Casting
 Cold Chamber Die Casting
 Centrifugal Casting
 True Centrifugal Casting
 Semi centrifugal Casting

 Centrifuge Casting

 Special Casting Technique – Squeeze Casting

 Casting defects
 Casting economics
 Casting characteristic chart
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BASIC PERMANENT MOLD CASTING

 Basic Permanent Mold Casting is a generic term used to describe all

permanent mold casting processes. They main similarity of this
group being the employment of a permanent mold that can be used
repeatedly for multiple castings. The mold also called a die is
commonly made of steel or iron, but other metals or ceramics can
be used. Parts that may be manufactured in industry using this
casting process include cylinder blocks, cylinder heads, pistons,
connecting rods, parts for aircraft and rockets, gear blanks, and

kitchenware

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MOLD LIFE
 A significant amount of resources need to be utilized in the
production of the mold, making setup more expensive for permanent
mold manufacturing runs. However, once created, a permanent
mold may be used tens of thousands of times before its mold life is
up. Due to the continuous repetition of high forces and temperatures
all molds will eventually decay to the point where they can no longer
effectively manufacture quality castings. The number of castings
produced by that particular mold before it had to be replaced is
termed mold life . Many factors effect mold life such as the molds
operating temperature, mold material and casting metal

4
CORES AND SEMI PERMANENT MOLD CASTING

 Cores are often employed in a permanent mold casting process.

These cores are likely made of the same material of the mold and
are also permanent. The geometry of the these cores has to allow
for the removal of the casting or the cores need to be able to
collapse by some mechanical means. Sand cores have a lot less
limitations and can be used in conjunction with permanent molds.
Sand cores are placed within the permanent mold prior to pouring
the metal casting. The sand cores are not permanent, like the mold,
and must be broken up and replaced with every casting. Sand
cores, however, allow for more freedom in the manufacture of
internal geometry. In manufacturing industry using a disposable core
with a permanent mold is called semi permanent mold casting

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STEP BY STEP PROCESS – PERMANENT MOLD
CASTING

 STEP-1 MOLD CREATION When planning to manufacture using a

permanent mold manufacturing process the first step is to create the
mold. The sections of the mold are most likely machined from two
separate blocks. These parts are manufactured precisely. They are
created so that they fit together and may be opened and closed
easily and accurately. The gating system as well as the part
geometry is machined into the mold

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STEP-1 MOLD CREATION PICTORIAL DESCRIPTION

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STEP -2

 STEP-2 Before pouring the casting the internal surfaces of the

permanent mold are sprayed with a slurry consisting of refractory
materials suspended in liquid. This coating serves as a thermal
gradient helping to control the heat flow, and acting as a lubricant for
easier removal of the cast part. In addition applying the refractory
coat as a regular part of the manufacturing process will increase the
mold life of the very valuable mold

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STEP-2 PICTORIAL DESCRIPTION

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 STEP-3 The two parts of the mold must be closed and held
together with force, using some sort of mechanical means. Most
likely the mold will be heated prior to the pouring of the metal
casting. A possible temperature that a permanent metal casting
mold may be heated before pouring could be around 350F (175C).
The heating of the mold will facilitate the smoother flow of the liquid
metal through the molds gating system and casting cavity. Pouring a
metal casting in a heated mold will also reduce the thermal shock
encountered by the mold due to the high temperature gradient
between the molten metal and the mold. This will act to increase
mold life. Once securely closed and heated the permanent mold is
ready for the pouring of the cast part

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STEP-3 PICTORIAL DESCRIPTION

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STEP-4 SOLIDIFICATION

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STEP -5

 STEP -5 CAST PART REMOVAL In manufacturing practice the

cast part is usually removed before much cooling occurs to prevent
the solid metal casting from contracting too much in the mold. This is
done to prevent cracking the casting since the permanent mold does
not collapse. (see Shrinkage ) The removal of the casting is
accomplished by way of ejector pins built into the mold

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STEP -5 CAST REMOVAL PICTORIAL DESCRIPTION

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BASIC PERMANENT MOLD CASTING SUMMARY

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CONSIDERATIONS PERMANENT MOLD CASTING
 Generally this manufacturing process is only suited for materials
with lower melting temperatures, such as zinc, copper, magnesium,
and aluminum alloys.

 Cast iron parts are also manufactured by this process but the high
melting temperature of cast iron is hard on the mold.

 Steels may be cast in permanent molds made of graphite or some

special refractory material.

 The mold may be cooled by water or heat fins to help the dissipation
of heat during the casting process.

 Due to the need to open and close the mold to remove the work
piece, part geometry is limited.

 If the semi permanent casting method is used internal part geometry

may be complex. 16
Contd…..

 Due to the nature of the mold the metal casting will solidify rapidly.
This will result in a smaller grain structure producing a casting with
superior mechanical properties.

 More uniform properties throughout the material of the cast part may
also be observed with permanent mold casting.

 Closer dimensional accuracy as well as excellent surface finish of

the part, is another advantage of this manufacturing process.

 In industrial manufacture permanent mold casting results in a lower

percentage of rejects than many expendable mold processes.

 There is a limitation on the size of cast parts manufactured by this

process.

17
Contd…

 The initial setup cost are high making permanent mold casting
unsuitable for small production runs.

 Permanent Mold Casting can be highly automated.

 This manufacturing process is useful in industry for high volume

runs. Where once set up, it can be extremely economical with a high
rate of production

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SLUSH CASTING
 Slush casting is a variant of permanent molding casting to create a
hollow casting or hollow cast. In the process the material is poured
into the mold and allowed to cool until a shell of material forms in the
mold. The remaining liquid is then poured out to leave a hollow
shell. The resulting casting has good surface detail but the wall
thickness can vary. The process is usually used to cast ornamental
products, such as candlesticks, lamp bases, and statuary, from low-
melting-point materials. A similar technique is used to make hollow
chocolate figures for Easter and Christmas.

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SLUSH CASTING STEP BY STEP PROCESS
 STEP -1 Mold preparation

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 STEP-2 POURING OF MOLTEN METAL

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STEP-3 SOLIDIFICATION The main principle of this casting process
relies on the fact that when a metal casting hardens in a mold, it will
solidify from the mold wall towards the inside of the casting. In other
words a metal skin forms first, (as the external geometry of the part). This
skin thickens as more of the metal casting's material converts to a solid
state

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STEP-3 SOLIDIFICATION

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 STEP-3 SOLIDIFICATION TIME PHASE PICTORIAL
DESCRIPTION

No thickness Increase
after time T1 Thickness
after time T2

Desired
Thickness
after time T3
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STEP – 4 POURING OUT OF MOLTEN METAL

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27
CORTHIAS CASTING
 Corthias Casting: Corthias Casting is another variation of the
permanent mold casting, where a plunger is used to pack down the
molten metal form the sprue hole. This allows for thinner walls and
greater details to be produced.

 This method of casting resembles the slush casting but differs

somewhat in procedure. A definite amount of metal is poured into an
open-ended mold, and a close fitting core is forced into the cavity
pressurizing the metal into the mold cavities. The core is removed
as soon as the metal sets, leaving a hollow thin walled casting. This
process was developed in France by Corthias, is limited to
ornamental casting of open design. on-metallic molds are used with
both high & low temperature allows

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PRESSURE CASTING/LOW PRESSURE CASTING

 Pressure Casting also known in manufacturing industry as low

pressure casting or pressure pouring is another variation of
permanent mold casting. Instead of pouring the molten metal into
the casting and allowing gravity to be the force that distributes the
liquid material through the mold, pressure casting uses air pressure
to force the metal through the gating system and the casting's cavity.

 This process can be used to cast high quality manufactured parts.

Often steel metal castings are cast in graphite molds using this
process. For example in industry steel railroad car wheels are cast
with this method Used a graphite or metal mold

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LOW PRESSURE CASTING PICTORIAL DESCRIPTION

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LOW PRESSURE CASTING- PICTORIAL
DESCRIPTION

(a) The bottom-pressure casting process utilizes graphite molds for the
productin of steel railroad wheels. (b) Gravity pouring method of
casting a railroad wheel. Note that the pouring basin also serves as a
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riser.
PROPERTIES AND CONSIDERATIONS LOW
PRESSURE CASTING
 Low Pressure casting manufacture can be used to produce castings with
superior mechanical properties, good surface finish, and close dimensional
accuracy.

 Like in other permanent mold methods the mold needs to be able to open
and close for removal of the work piece. Therefore very complicated casting
geometry is limited.

 Since the refractory tube is submersed in the molten material, the metal
drawn for the casting comes from well below the surface. This metal has
had less exposure to the environment than the material at the top. Gas
trapped in the metal as well as oxidation effects are greatly reduced.

 The high setup cost makes pressure casting not efficient for small runs, but
an excellent productivity rate makes it suitable for large batch manufacture.

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VACUUM PERMANENT MOLD CASTING

 Similar to low pressure casting, but vacuum pressure is used to fill

the mold. As a result, finer details and thin walls can be molded and
the mechanical properties of the castings are improved.

 A permanent mold containing the part geometry and the gating

system is created, (usually accurately machined), similar to the mold
employed in the other permanent mold processes. The mold in
vacuum mold casting is much like the mold in the pressure casting
manufacturing process in that the gating system is designed so that
the flow of molten material starts at the bottom and flows upwards

33
MOLD FOR VACUUM CASTING

34
The mold is suspended over a supply of liquid metal for the
casting by some mechanical device, possible a robot arm

35
A vacuum force is applied to the top of the mold. The reduced pressure within the
mold causes molten metal to be drawn up through the gating system and casting
cavity As the casting solidifies, the mold is withdrawn from its position over the

molten metal and opened to release the casting

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PROPERTIES/CONSIDERATIONS IN VACUUM
PERMANENT MOLD CASTING

 This manufacturing process can produce castings with close

dimensional accuracy, good surface finish, and superior mechanical
properties.

 Castings with thin walled sections may be manufactured using this

technique.

 This process is very much like pressure casting in the way the mold
is filled, but since vacuum force is used instead of air pressure gas
related defects are greatly reduced.

 Set up cost make this manufacturing process more suitable to high

volume production, instead of small batch manufacture

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DIE CASTING

 Die Casting is a permanent mold manufacturing process that was

developed in the early 1900's. Die Casting manufacture is
characteristic in that it uses large amounts of pressure to force
molten metal through the mold. Since so much pressure is used to
ensure the flow of metal through the mold, castings with great
surface detail, dimensional accuracy, and extremely thin walls can
be produced. Wall thickness within castings can be manufactured as
small as .02in (.5mm). The size of industrial metal castings created
using this process vary from extremely small to around 50lbs.

 Typical parts made in industry by die casting include tools, toys,

carburetors, machine components, various housings, and motors

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THE PROCESS/MAIN COMPONENTS
 THE MOLD Like in all permanent mold manufacturing
processes the first step in die casting is the production of the mold.
The mold must be accurately created as two halves that can be
opened and closed for removal of the casting similar to the basic
permanent mold casting process. The mold for die casting is
commonly machined from steel and contains all the components of
the gating system. Multi cavity die are employed in manufacturing
industry to produce several castings with each cycle. Unit dies which
are a combination of smaller dies are also used to manufacture
castings in industry.
 Due to the extreme pressures and the continuous exposure to
thermal gradients from the molten metal, wearing of the die can be a
problem. However in a well maintained manufacturing process a die
can last hundreds of thousands of cycles before needing to be
replaced.

39
DIE CASTING MACHINES USE FOR INJECTION OF
MOLTEN METAL
 In addition to the opening and closing of the mold to prepare for and
remove castings, it is very important that there is enough force that
can be applied to hold the two halves of the mold together during the
injection of the molten metal. Flow of molten metal under such
pressures will create a tremendous force acting to separate the die
halves during the process. Die Casting Machines are large and
strong, designed to hold the mold together against such forces
 There are two main types of die casting machines - hot chamber
machines (used for alloys with low melting temperatures, such as
zinc) and cold chamber machines (used for alloys with high melting
temperatures, such as aluminum).
 Each process will be discussed specifically in more detail later.
Although these processes vary from each other both employ a
piston or plunger to force molten metal to travel in the desired
direction.

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HOT CHAMBER DIE CASTING MACHINE -PICTORIAL
DESCRIPTION

41
COLD CHAMBER DIE CASTING MACHINE -PICTORIAL
DESCRIPTION

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BASIC PRINCIPLE DESCRIPTION

 The pressure at which the metal is forced to flow into the mold in die
casting manufacture is on the order of 1000psi to 50000psi (7MPa to
350MPa). This pressure is accountable for the tremendously
intricate surface detail and thin walls that are often observed in
castings manufactured with this technique

 Once the mold has been filled with molten metal the pressure is
maintained until the casting has hardened. The mold is then opened
and the casting is removed. Ejector pins built into the mold assist in
the removal of the casting. In most manufacturing operations the
internal surfaces of the mold are sprayed with a lubricant before
every cycle. The lubricant will assist in cooling down the dies as well
as preventing the metal casting from sticking to the mold.

43
Contd….
 After the casting has been removed and the lubricant applied to the
mold surfaces the die are clamped together again then the cycle will
repeat itself. Cycle times will differ depending upon the details of
each specific die casting manufacturing technique. In some
instances very high rates of production have been achieved using
this process

 Pictorial description on next slide

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BASIC PRINCIPLE DIE CASTING PICTORIAL
DESCRIPTION

45
PROPERTIES/CONSIDERATIONS DIE CASTING

 Castings with close tolerances, tremendous, surface detail, and thin

intricate walls can be manufactured using this process.

 Due to the rapid cooling at the die walls smaller grain structures are
formed resulting in manufactured castings with superior mechanical
properties. This is especially true of the thinner sections of the
casting.

 In manufacturing industry it is of concern to keep the mold cool. Die

may have special passages built into them that water is cycled
through in order to keep down thermal extremes.

 High production rates are possible in die casting manufacture

46
Contd..

 Since mold is not permeable adequate vents need to be provided for

the elimination of gases during the casting process. These vents are
usually placed along the parting line between the die.

 Due to the high pressures a thin flash of metal is usually squeezed out
at the parting line. This flash has to be trimmed latter from the casting.

 Ejector pins will usually leave small round marks on the casting. These
can be observed on the surfaces of manufactured parts.

 The need to open and close the mold limits some of the shapes and
casting geometries that may be cast with this process.

 Equipment cost for die casting are generally high

47
Contd…

 Die casting manufacture can be highly automated making labor cost

low.

 Die casting is similar to most other permanent mold manufacturing

processes in that high set up cost, and high productivity make it
suitable for large batch manufacture and not small production run

48
HOT CHAMBER DIE CASTING

 Hot chamber die casting is one of the two main techniques in the
manufacturing process of die casting

 In hot chamber die casting manufacture the supply of molten metal

is attached to the die casting machine and is an integral part of the
casting apparatus for this manufacturing operation.

 Step by step procedure on next slide

49
The shot cylinder provides the power for the injection stroke. It is located above
the supply of molten metal. The plunger rod goes from the shot cylinder down to
the plunger, which is in contact with the molten material. At the start of a casting
cycle the plunger is at the top of a chamber (the hot-chamber). Intake ports allow

this chamber to fill with liquid metal

50
As the cycle begins the power cylinder forces the plunger downward. The plunger
travels past the ports cutting off the flow of liquid metal to the hot chamber. Now
there should be the correct amount of molten material in the chamber for the

"shot" that will be used to fill the mold and produce the casting

51
At this point the plunger travels further downward forcing the molten metal into
the die. The pressure exerted on the liquid metal to fill the die in hot chamber die
casting manufacture usually varies from about 700psi to 5000psi (5MPa to 35

MPa). The pressure is held long enough for the casting to solidify

52
In preparation for the next cycle of casting manufacture the plunger travels back
upward in the hot chamber exposing the intake ports again and allowing the

chamber to refill with molten material

53
CONSIDERATION IN HOT CHAMBER CASTING

 Hot chamber die casting has the advantage of a very high rate of
productivity. During industrial manufacture by this process one of the
disadvantages is that the setup requires that critical parts of the
mechanical apparatus, (such as the plunger), must be continuously
submersed in molten material. Continuous submersion in a high
enough temperature material will cause thermal related damage to
these components rendering them inoperative.

 For this reason usually only lower melting point alloys of lead, tin,
and zinc are used to manufacture castings with the hot chamber die
casting process

54
COLD CHAMBER DIE CASTING
 Cold chamber die casting is the second of the two major branches of
the die casting manufacturing process

 Cold chamber die casting is a permanent mold casting process, a

reusable mold gating system and all is employed. It is most likely
machined precisely from two steel blocks. Large robust machines
are used to exert the great clamping force necessary to hold the two
halves of the mold together against the tremendous pressures
exerted during the manufacturing process

 Step by step procedure on next slide

55
A metal shot chamber (cold-chamber) is located at the entrance of the mold. A

piston is connected to this chamber which in turn is connected to a power cylinder

56
At the start of the manufacturing cycle the correct amount of molten material for a
single shot is poured into the shot chamber from an external source holding the

material for the casting

57
The power cylinder forces the piston forward in the chamber cutting off the intake
port. The power cylinder moves the piston forward which forces the molten
material into the metal casting mold with great pressure. The pressure causes the
liquid metal to fill in even thin sections of the casting and press the mold walls for
great surface detail. The pressure is maintained even after the injection phase of

casting manufacture

58
COLD CHAMBER MACHINE – PICTORIAL VIEW

59
COLD CHAMBER PROCESS CONSEDRATIONS
 Once the metal casting begins to solidify the pressure is released.
Then the mold is opened and the casting is removed by way of
ejector pins. The mold is sprayed with lubricant before closing again,
and the piston is withdrawn in the shot chamber for the next cycle of
casting production

 Higher melting point alloys of aluminum, brass, copper, and

aluminum-zinc are often cast in manufacturing industry using cold
chamber die casting. It is very possible to manufacture castings from
lower melting point alloys using the cold-chamber process.
However, considering industrial metal casting manufacture however
the advantages of casting production by the hot-chamber process
usually make it the more suitable choice for lower melting point alloy

60
DIFFERENCE BETWEEN HOT AND COLD CHAMBER
 The main difference between cold-chamber die casting and hot-
chamber die casting manufacture is that in cold-chamber die casting
the molten metal for the casting is introduced to the shot chamber
from an external source, while in hot chamber casting the source of
molten material is attached to the machine. In the hot-chamber
process certain machine apparatus is always in contact with molten
metal.

 For this reason higher melting point materials will create a problem
for the machinery in a hot-chamber metal casting setup. Since the
liquid metal is brought in from an outside source, the die casting
machinery is able to stay much cooler in a cold-chamber process.

61
PROCESS CAPABILITIES AND DIES SELECTION

 Dies are rated according to their clamping force that is needed

 Factors involved in selection of die cast machines are
 Die size
 Piston stroke
 Shot pressure
 Cost
 Die-casting dies
 Single cavity
 Multiple-cavity
 Combination-cavity
 Unit dies
 Surface cracking is a problem with dies due to the hot metal that
is poured in to them
 Has ability to produce strong high- quality parts with complex
shapes
 Good dimensional accuracy and surface details

62
VARIOUS TYPES OF CAVITIES IN A DIE CASTING DIE.

a) Single – cavity
die

b) Multiple – cavity
die

c) Combination die

63
800 ton hot chamber die casting machine, DAM 8005. This is the largest
hot chamber machine in the world and costs about $1.25 million.

64
DIE CAST PRODUCTS - EXAMPLES

65
CENTRIFUGAL CASTING
 The main principle behind any centrifugal casting is metal that is
poured in to a rotating mold exactly at center is thrown outward due
to the action of centrifugal force. The main advantage of centrifugal
casting is the impurities get accumulated exactly at the center. The
types of centrifugal castings are

 TRUE CENTRIFUGAL CASTING

 SEMI CENTRIFUGAL CASTING
 CENTRIFUGING CASTING

66
TRUE CENTRIFUGAL CASTING

 Centrifugal casting, sometimes called rotocasting, is a metal casting

process that uses centrifugal force to form cylindrical parts. This
differs from most metal casting processes, which use gravity or
pressure to fill the mold. In centrifugal casting, a permanent mold
made from steel, cast iron, or graphite is typically used. However,
the use of expendable sand molds is also possible. The casting
process is usually performed on a horizontal centrifugal casting
machine (vertical machines are also available).

 Basically, this casting technique is employed when axis symmetrical

objects with uniform diameter are to be produced. Core is not
employed in these casting

 Step by step process is covered in coming slides

67
STEP BY STEP PROCESS TRUE CENTIFUGAL
CASTING

 MOLD PREPARATION - The walls of a cylindrical mold are first

coated with a refractory ceramic coating, which involves a few steps
(application, rotation, drying, and baking). Once prepared and
secured, the mold is rotated about its axis at high speeds (300-3000
RPM), typically around 1000 RPM.

 POURING - Molten metal is poured directly into the rotating mold,

without the use of runners or a gating system. The centrifugal force
drives the material towards the mold walls as the mold fills.

 COOLING - With all of the molten metal in the mold, the mold
remains spinning as the metal cools. Cooling begins quickly at the
mold walls and proceeds inwards.

68
Contd…

 CASTING REMOVAL - After the casting has cooled and solidified,

the rotation is stopped and the casting can be removed.

 FINISHING - While the centrifugal force drives the dense metal to

the mold walls, any less dense impurities or bubbles flow to the
inner surface of the casting. As a result, secondary processes such
as machining, grinding, or sand-blasting, are required to clean and
smooth the inner diameter of the part

69
PICTORIAL DESCRIPTION TRUE CENTRIFUGAL
CASTING

70
71
72
73
APPLICATION OF TRUE CENTRIFUGAL CASTING

 Centrifugal casting has many applications in manufacturing industry

today. The process has several very specific advantages. Cast parts
manufactured in industry include various pipes and tubes, such as
sewage pipes, gas pipes, and water supply lines, also bushings,
rings, the liner for engine cylinders, brake drums, and street lamp
posts. The molds used in true centrifugal casting manufacture are
round, and are typically made of iron, steel, or graphite. Some sort
of refractory lining or sand may be used for the inner surface of the
mold.

74
CONSIDERATION/PROPERTIES TRUE
CANTRIFUGAL CASTING
 True centrifugal casting is a great manufacturing process for
producing hollow cylindrical parts.

 The casting's wall thickness is controlled by the amount of material

added during the pouring phase.

 Rotational rate of the mold during the manufacture of the casting

must be calculated carefully based on the mold dimensions and the
metal being cast

 This manufacturing operation produces cast parts without the need

for sprues, risers, or other gating system elements, making this a
very efficient casting process in manufacturing industry in terms of
material usage

75
Contd….

 Since large forces press the molten material for the cast part against
the mold wall during the manufacturing operation, great surface
finish and detail are characteristic of true centrifugal casting

 Quality castings with good dimensional accuracy can be produced

with this process.

 Material of high density and with few impurities is produced in the

outer regions of cylindrical parts manufactured by true centrifugal
casting

 This method can produce very large castings. Cylindrical pipes 10

feet in diameter and 50 feet long have been manufactured using this
technique

 This is batch production operation.

76
SEMI CENTRIFUGAL CASTING

 Semi centrifugal casting manufacture is a variation of true centrifugal

casting. The main difference is that in semi centrifugal casting the
mold is filled completely with molten metal, which is supplied to the
casting through a central sprue/gating system and use of central
core
 low spinning speeds can be used speeds ranging between 180 to
200 RPM is recommended. These castings are normally prepared in
vertical machines. The mold cavity is arranged with in the mold so
that its central axis is vertical and concentric with the axis of rotation.
Gating system is employed in the casting for having a directional
solidification.
 Castings manufactured by this process will possess rotational
symmetry e.g. wheels. Much of the details of the manufacturing
process of semi centrifugal casting are the same as those of true
centrifugal casting
 Step by step process is discusses on next slides

77
In semi centrifugal casting manufacture a permanent mold may be
employed. However often industrial manufacturing processes will utilize
an expendable sand mold. This enables the casting of parts from high

temperature material

78
The molten material for the metal casting is poured into a pouring basin
and is distributed through a central sprue to the areas of the mold. The
forces generated by the rotation of the mold ensure the distribution of

molten material to all regions of the casting

79
As the casting solidifies in a rotating mold, the centripetal forces
constantly push material out from the central sprue/riser. This material

acts to fill vacancies as they form thus avoiding shrinkage areas

80
The high forces in the outer section that push the molten material against
the mold wall also ensure a great surface finish of cast parts manufactured
by semi centrifugal casting. Another feature of this process, attributed to
the usage of centripetal forces, is that impurities within the metal, (such as
solid inclusions and trapped air), will form towards the inner regions of the
casting. This particular detail is also a feature in other types of centrifugal

casting manufacture

81
In industrial manufacture of parts by semi centrifugal casting it is
common to machine out the impurity filled center section, leaving only the

purer, denser outer region as the final cast part.

82
SEMI CENTRIFUGAL CASTING PICTORIAL
DESCRIPTION

83
CENTRIFUGING CASTING

 Centrifuging is used for forcing metal from a central axis of the

equipment into individual mold cavities that are placed on the
circumference. This provides a means of increasing the filling
pressure within each mold and allows for reproduction of intricate
details. This method is often used for the pouring of investment
casting pattern.

 The process is used for smaller parts and radial symmetry of the
part is not the requirement as in case of other two centrifugal casting

84
CENTRIFUGE CASTING-PICTORIAL DESCRIPTION

85
SPECIAL CASTING PROCESS- SQUEEZE CASTING

 Squeeze casting, also known as liquid metal forging, is a

combination of casting and forging process

 The molten metal is poured into the bottom half of the pre-heated
die. As the metal starts solidifying, the upper half closes the die and
applies pressure during the solidification process. The amount of
pressure thus applied is significantly less than used in forging, and
parts of great detail can be produced. Coring can be used with this
process to form holes and recesses. The porosity is low and the
mechanical properties are improve

 Both ferrous and non-ferrous materials can be produced using this

method

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SQUEEZE CASTING-PICTORIAL DESCRIPTION

(c) Close die and

apply pressure

(a) Melt Metal

(d) Eject squeeze
casting and
charge melt
stock and
repeat cycle

Sequence of operations in the squeeze-casting

(b) Pour molten process. This process combines the
metal into die advantages of casting and forging.
87
ASSIGNMENT NO.1
 Q10. Since die casting involve use of force so what is the approx
weight ratio relation ship between cast part and mold weight and
reasons for that?

 Q11 In your opinion which one out of hot and cold chamber die
casting will provide high rate of production and why ? Also discuss
pressure requirement for both type of casting.

 Q12.What would happen if rotational speed in true centrifugal

casting is slow?

 Q13.How shrinkage problem of metal is handled in true centrifugal

casting

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COMMON CASTING DEFECTS

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COMMON CASTING DEFECTS

 There are numerous opportunities for things to go wrong in a casting

operation, resulting in quality defects in the product

 The defects can be classified as follows:

 Defects common to all casting processes
 Defects related to sand casting process

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COMMON CASTING DEFECTS- MISRUN
 A casting that has solidified before completely filling mold cavity

91
COMMON CASTING DEFECTS- COLD SHUT

 Two portions of metal flow together but there is a lack of fusion due
to premature freezing

92
COMMON CASTING DEFECTS- COLD SHOTS

 Metal splatters during pouring and solid globules form and become
entrapped in casting

93
COMMON CASTING DEFECTS- SHRINKAGE CAVITY
 Depression in surface or internal void caused by solidification
shrinkage that restricts amount of molten metal available in last
region to freeze

94
COMMON CASTING DEFECTS- HOT TEAR

 A hot tear is a fracture formed during solidification because of

hindered contraction

95
 COMMON CASTING DEFECT-POROSITY

 Network of small voids distributed throughout the casting

96
COMMON CASTING DEFECTS- SUMMARY

97
COMMON SAND CASTING DEFECTS - SAND BLOW
 Balloon-shaped gas cavity caused by release of mold gases during
pouring

98
COMMON SAND CASTING DEFECTS PIN HOLES
 Formation of many small gas cavities at or slightly below surface of
casting

99
COMMON SAND CASTING DEFECTS - PENETRATION

 When fluidity of liquid metal is high, it may penetrate into sand mold
or sand core, causing casting surface to consist of a mixture of sand
grains and metal

100
COMMON SAND CASTING DEFECTS-MOLD SHIFT

 A step in cast product at parting line caused by sidewise relative

displacement of cope and drag

101
COMMON SAND CASTING DEFECTS - SUMMARY

102
CASTING ECONOMICS

103
CASTING COST OF DIFFERENT PROCESS

104
COMPONENT COST VS NUMBER OF COMPONENTS
OF DIFFERENT PROCESSES

105
CASTING CHARACTERISTICS

106
THANKYOU

107